Plastic pallet system

Abstract

A plastic pallet system is provided for the support, storage, and transportation of articles. The plastic pallet system includes a plurality of top boards and a plurality of runner assemblies. Both the plurality of top boards and the plurality of runner assemblies may be formed of plastic. A method for manufacturing the plastic pallet system is also provided.

1. A pallet system comprising:
 a plurality of top boards having an elongated planar configuration, the plurality of top boards formed of plastic; and 
 a plurality of runner assemblies formed of plastic and positioned in spaced relation beneath the plurality of top boards, each of the plurality of runner assemblies extending between a first terminal end and a second terminal end along a runner axis, the runner axis oriented generally transversely to the plurality of top boards, each of the plurality of runner assemblies comprising:
 a top runner board; 
 a bottom runner board; 
 a first runner support extending between the top and bottom runner boards; and 
 a second runner support spaced apart from the first runner support and extending between the top and bottom runner boards, the first and second runner supports being spaced the same distance from the first terminal end of the runner assembly. 
 
 
     
     
       2. The pallet system of  claim 1 , wherein the top and bottom runner boards have a generally similar configuration as the plurality of top boards. 
     
     
       3. The pallet system of  claim 1 , further comprising a plurality of bottom boards positioned beneath the plurality of runner assemblies, the runner axis oriented generally transversely to the plurality of bottom boards. 
     
     
       4. The pallet system of  claim 1 , wherein the first and second runner supports are located between adjacent top boards. 
     
     
       5. The pallet system of  claim 1 , wherein the first and second runner supports are arranged in parallel to each other and in a direction perpendicular to the runner axis. 
     
     
       6. The pallet system of  claim 1 , wherein the first and second runner supports are located side-by-side between the top and bottom runner boards. 
     
     
       7. The pallet system of  claim 1 , wherein the top runner board has opposing side walls that extend parallel to the runner axis, the first and second runner supports being located between the opposing side walls of the top runner board. 
     
     
       8. The pallet system of  claim 1 , wherein the bottom runner board has opposing side walls that extend parallel to the runner axis, the first and second runner supports being located between the opposing side walls of the bottom runner board. 
     
     
       9. The pallet system of  claim 1 , wherein the first and second runner supports comprise hollow tubes. 
     
     
       10. The pallet system of  claim 1 , further comprising:
 a third runner support extending between the top and bottom runner boards; and 
 a fourth runner support spaced apart from the third runner support and extending between the top and bottom runner boards, the third and fourth runner supports spaced the same distance from the first terminal end of the runner assembly. 
 
     
     
       11. The pallet system of  claim 10 , wherein the first and second runner supports are located closer to the first terminal end of the runner assembly than the third and fourth runner supports. 
     
     
       12. The pallet system of  claim 11 , wherein the first and second runner supports are located side-by-side between the top and bottom runner boards and the third and fourth runner supports are located side-by-side between the top and bottom runner boards. 
     
     
       13. A pallet system comprising:
 a plurality of top boards having an elongated planar configuration, the plurality of top boards formed of plastic; and 
 a plurality of runner assemblies formed of plastic and positioned in spaced relation beneath the plurality of top boards, each of the plurality of runner assemblies extending between a first terminal end and a second terminal end along a longitudinal runner axis, the longitudinal runner axis oriented generally transversely to the plurality of top boards, each of the plurality of runner assemblies comprising:
 a top runner board; 
 a bottom runner board; 
 a first runner support extending between the top and bottom runner boards; and 
 a second runner support spaced apart from the first runner support and extending between the top and bottom runner boards, the first and second runner supports being arranged in parallel to each other and in a direction perpendicular to the longitudinal runner axis. 
 
 
     
     
       14. The pallet system of  claim 13 , wherein the top runner board has opposing side walls that extend parallel to the longitudinal runner axis, the first and second runner supports being located between the opposing side walls of the top runner board. 
     
     
       15. The pallet system of  claim 13 , wherein the bottom runner board has opposing side walls that extend parallel to the longitudinal runner axis, the first and second runner supports being located between the opposing side walls of the bottom runner board. 
     
     
       16. A pallet system comprising:
 a plurality of top boards having an elongated planar configuration, the plurality of top boards formed of plastic, each top board including a top wall, a bottom wall that extends substantially parallel to the top wall, and first and second side walls joining the top and bottom walls, the top wall, the bottom wall, and the first and second side walls of each top board cooperating to define a substantially hollow interior, the first side wall of at least an outer-most one of the plurality of top boards having an inner surface that faces the hollow interior and an outer surface opposite the inner surface, the inner surface extending from the top wall to the bottom wall in a direction perpendicular to the top and bottom walls, whereby the top and bottom walls are horizontally aligned at opposing ends of the first side wall, at least a portion of the outer surface deviating from the direction perpendicular to the top and bottom walls at a location between the top and bottom walls; and 
 a plurality of runner assemblies formed of plastic, the plurality of runner assemblies positioned beneath the plurality of top boards and extending generally transversely to the plurality of top boards, each of the plurality of runner assemblies comprising:
 a top runner board; 
 a bottom runner board; and 
 a plurality of runner supports extending between the top and bottom runner boards. 
 
 
     
     
       17. The pallet system of  claim 16 , further comprising a plurality of bottom boards positioned beneath the plurality of runner assemblies, the plurality of bottom boards extending generally transversely to the plurality of runner assemblies and generally parallel to the plurality of top boards. 
     
     
       18. The pallet system of  claim 16 , wherein the portion of the outer surface that deviates from the direction perpendicular to the top and bottom walls extends from at least one of the top and bottom walls to a location approximately midway between the top and bottom walls. 
     
     
       19. The pallet system of  claim 16 , wherein the plurality of runner supports of each runner assembly are arranged in pairs, the paired runner supports being spaced an equal distance from a terminal end of the runner assembly. 
     
     
       20. The pallet system of  claim 16 , wherein the plurality of runner supports of each runner assembly are arranged in parallel rows, the rows being spaced apart to accommodate passage of a forklift.